Rechargeable battery features and components

ABSTRACT

Energy storage devices, battery cells, and batteries of the present technology may include a housing characterized by a first end and a second end opposite the first end. The housing may include a circumferential indentation proximate the first end. The housing may define a first interior region between the first end and the circumferential indentation, and the housing may define a second interior region between the circumferential indentation and the second end. The batteries may include a set of electrodes located within the housing. The set of electrodes may be positioned within the second interior region of the housing. The batteries may include a cap at least partially contained within the first interior region of the housing. The batteries may also include a first insulator positioned within the housing. The first insulator may extend across the circumferential indentation from the cap to the set of electrodes.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/500,271, filed May 2, 2017, which is hereby incorporated by referencein its entirety for all purposes.

TECHNICAL FIELD

The present technology relates to batteries and battery components. Morespecifically, the present technology relates to features and componentsof a rechargeable battery.

BACKGROUND

In battery-powered devices, active device use can produce scenariosenhancing wear on the device. Batteries within the device may be exposedto more intense circumstances and environments than predecessor designs.Improved designs are needed.

SUMMARY

The present technology relates to energy storage devices, includingbattery cells and batteries, which may include a housing characterizedby a first end and a second end opposite the first end. The housing mayinclude a circumferential indentation proximate the first end. Thehousing may define a first interior region between the first end and thecircumferential indentation, and the housing may define a secondinterior region between the circumferential indentation and the secondend. The batteries may include a set of electrodes located within thehousing. The set of electrodes may be positioned within the secondinterior region of the housing. The batteries may include a cap at leastpartially contained within the first interior region of the housing. Thecap may be characterized by a first surface facing the set ofelectrodes. The batteries may also include a first insulator positionedwithin the housing. The first insulator may extend across thecircumferential indentation from the cap to the set of electrodes. Thefirst insulator may be characterized by a first outer radius at a firstend proximate the cap, and the first insulator may be characterized by asecond outer radius greater than the first outer radius at a second endproximate the set of electrodes.

In some embodiments, the set of electrodes may include a separatordefining a height of the set of electrodes. The first insulator may bepositioned within the housing in contact with the separator. The firstinsulator may compress the separator within the housing. The firstinsulator may be characterized by a chamfered edge extending to thefirst end of the first insulator. The first insulator may be of a sizeconfigured to maintain a portion of the first insulator characterized bythe chamfered edge between the circumferential indentation of thehousing and an exterior component of the set of electrodes at all times.The batteries may further include an electrode tab extending between andcontacting both the set of electrodes and the cap. The electrode tab maybe coupled with the cap along the first surface of the cap at a firstend of the electrode tab, and the first end of the electrode tab may becharacterized by chamfered edges. The electrode tab may be fixedlycoupled with the cap at a position on the electrode tab centrallylocated between the chamfered edges.

Exemplary batteries may further include an electrode tab coupled betweenthe set of electrodes and an interior surface of the housing. Theelectrode tab may be coupled with the housing in the second interiorregion proximate the circumferential indentation. The coupling of theelectrode tab may include a three-point weld. The electrode tab may befixedly coupled with an anode current collector of the set of electrodesalong a first surface of the anode current collector. An insulating tapemay be positioned on a second surface of the anode current collectoropposite the first surface over a portion of the anode current collectorto which the electrode tab is coupled. The insulating tape may extendalong the second surface of the anode current collector towards an anodeactive material located on the second surface of the anode currentcollector. The batteries may also include a second insulator positionedalong a base of the housing between the set of electrodes and thehousing. The second insulator may be characterized by an outer diameterless than an outer diameter of the set of electrodes. The set ofelectrodes may include a rolled configuration including couplingmaterial extending about an exterior surface of the set of electrodesand characterized by a first end of the coupling material overlapping asecond end of the coupling material. In embodiments, the battery mayinclude a rolled configuration, and may include a cathode currentcollector. The battery may also include a cathode active materialpositioned on a portion of the cathode current collector. The batterymay further include an insulating tape covering an end of the cathodeactive material and extending to an exterior edge along a length of thecathode current collector.

The present technology may also encompass batteries including a set ofelectrodes. The batteries may include a cap. The batteries may furtherinclude an electrode tab coupled with the set of electrodes at a firstend of the electrode tab. A first surface of the electrode tab may becoupled with a surface of the cap at a second end of the electrode tab.The second end of the electrode tab may be contained within aninsulative material.

In some embodiments, a first window may be defined within the insulativematerial along the first surface of the electrode tab. The first windowmay expose a portion of the electrode tab. The electrode tab may becoupled with the cap at the portion of the electrode tab exposed by thewindow defined within the insulative material. The insulative materialmay extend along the first surface of the electrode tab entirely aboutan exterior of the window. The electrode tab may be furthercharacterized by a second surface opposite the first surface of theelectrode tab. The electrode tab may be characterized by at least onesidewall extending between the first surface and the second surface. Theinsulative material may extend along the at least one sidewall. Theinsulative material may extend about the second surface of the electrodetab. A second window may be defined in the insulative material along thesecond surface. The second window may be located along the secondsurface opposite a position of the first surface where the first windowis defined in the insulative material.

The present technology may also encompass batteries including a housingcharacterized by a first end and a second end opposite the first end.The housing may include a circumferential indentation proximate thefirst end. The housing may define a first interior region between thefirst end and the circumferential indentation. The housing may alsodefine a second interior region between the circumferential indentationand the second end. The batteries may include a set of electrodeslocated within the housing, and the set of electrodes may be positionedwithin the second interior region of the housing. The batteries mayinclude a cap at least partially contained within the first interiorregion of the housing. The cap may be characterized by a first surfacefacing the set of electrodes. The batteries may include a firstelectrode tab coupled with the set of electrodes at a first end of theelectrode tab. A first surface of the electrode tab may be coupled witha surface of the cap at a second end of the electrode tab. The secondend of the electrode tab may be contained within an insulative material.A first window may be defined within the insulative material along thefirst surface of the electrode tab. The first end of the electrode tabmay be characterized by chamfered edges.

The batteries may include a second electrode tab coupled between the setof electrodes and an interior surface of the housing. The electrode tabmay be coupled with the housing in the second interior region proximatethe circumferential indentation. The batteries may also include a firstinsulator positioned within the housing. The first insulator may extendacross the circumferential indentation from the cap to the set ofelectrodes. The first insulator may be characterized by a first outerradius at a first end proximate the cap. The first insulator may becharacterized by a second outer radius greater than the first outerradius at a second end proximate the set of electrodes.

Such technology may provide numerous benefits over conventionaltechnology. For example, the present devices may expand and enhanceinsulation between components operating at different potential.Additionally, the designs may improve hardware configurations forsmaller batteries. These and other embodiments, along with many of theiradvantages and features, are described in more detail in conjunctionwith the below description and attached figures.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of the disclosedembodiments may be realized by reference to the remaining portions ofthe specification and the drawings.

FIG. 1 shows a schematic cross-sectional view of an energy storagedevice according to embodiments of the present technology.

FIG. 2 shows a schematic partial cross-sectional view of an energystorage device according to embodiments of the present technology.

FIG. 3 shows a schematic partial view of components of an energy storagedevice according to embodiments of the present technology.

FIG. 4 shows a schematic partial view of an electrode tab of an energystorage device according to embodiments of the present technology.

FIG. 5 shows a schematic partial cross-sectional view of an energystorage device according to embodiments of the present technology.

FIG. 6 shows a schematic partial view of a battery cell according toembodiments of the present technology.

FIG. 7 shows a schematic cross-sectional view of a portion of anelectrode according to embodiments of the present technology.

FIG. 8 shows a schematic cross-sectional view of a portion of anelectrode according to embodiments of the present technology.

FIGS. 9A-9C show schematic plan views of electrode tabs of an energystorage device according to embodiments of the present technology.

Several of the figures are included as schematics. It is to beunderstood that the figures are for illustrative purposes, and are notto be considered of scale unless specifically stated to be of scale.Additionally, as schematics, the figures are provided to aidcomprehension and may not include all aspects or information compared torealistic representations, and may include exaggerated material forillustrative purposes.

In the figures, similar components and/or features may have the samenumerical reference label. Further, various components of the same typemay be distinguished by following the reference label by a letter thatdistinguishes among the similar components and/or features. If only thefirst numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION

Batteries, battery cells, and more generally energy storage devices, maybe made from a host of materials. As battery-powered devices continue toshrink, internal batteries that power them are forced into ever smallerform factors as well. In one sense, a battery may be reduced in size byreducing capacity, or more specifically reducing the amount of activematerial contained within the battery. However, as consumers continue toexpect longer time of use in smaller designs, the amount of activematerial within a battery not only may be maintained, but designs mayseek to increase both the volume occupied by active material and theamount of power produced by the active material. Because of the tensionbetween volume within a battery and amount of space that may be used foractive material, space within the battery for other components may beconstrained even more.

In tandem with the physical reduction in device size is the more robustuse of devices. From phones, media players, and fitness devices, towireless components that may be used in conjunction with the devices,consumers are utilizing devices in daily activities that can expose thedevices to more intense conditions, including more routine bumping,dropping, weather exposure, as well as almost constant use. This mayrequire more robust designs and components for both the general deviceand the battery contained within the device. When the devices beingpowered are small, such as watches and fitness devices, or wirelessdevices requiring dedicated batteries such as earphones and healthmonitors, more robust designs can be difficult to produce when the scaleof the battery may be a few millimeters or less.

The present technology addresses many of these issues by incorporatingfeatures and components that may produce more robust battery designs,while limiting volume occupied by components aside from the cellmaterial. Many of the batteries described may be on a scale of a fewmillimeters or less, and internal components may be even smaller. Byutilizing particular components and configurations as describedthroughout the application, the present technology may provide morerobust designs that maintain high capacity for long periods of use.

Although the remaining portions of the description will routinelyreference batteries that may be on a relatively small scale, it will bereadily understood by the skilled artisan that the technology is not solimited. The present designs may be employed with any number of batteryor energy storage devices, including other rechargeable and primary, ornon-rechargeable, battery types, as well as electrochemical capacitorsalso known as supercapacitors or ultracapacitors. Moreover, the presenttechnology may be applicable to batteries and energy storage devicesused in any number of technologies that may include, without limitation,phones and mobile devices, wireless accessories including monitors,earphones, and speakers, handheld electronic devices, laptops and othercomputers, appliances, heavy machinery, transportation equipmentincluding automobiles, water-faring vessels, air travel equipment, andspace travel equipment, as well as any other device that may usebatteries or benefit from the discussed designs. Accordingly, thedisclosure and claims are not to be considered limited to any particularexample discussed, but can be utilized broadly with any number ofdevices that may exhibit some or all of the electrical or chemicalcharacteristics of the discussed examples.

FIG. 1 shows a schematic cross-sectional view of an energy storagedevice 100 according to embodiments of the present technology. FIG. 1illustrates a cylindrical battery, which may be a rechargeable batteryin embodiments, although energy storage device 100 may also be a primarybattery, such as an alkaline battery. Energy storage device 100 may bepartially or substantially cylindrical, although in embodiments energystorage device 100 may be rectilinear. In embodiments in which energystorage device 100 is rechargeable, the device may include a number ofbattery cell designs including a rolled configuration, such as a jellyroll as illustrated, although the battery cell may also be a stacked,prismatic, or pouch-style cell in other embodiments. Energy storagedevice 100 may include a housing 105. Housing 105 may include a firstend 107 and a second end 109 in embodiments.

Housing 105 may also define a circumferential indentation 108.Indentation 108 may extend entirely about housing 105, and may be anannular indentation, although in other geometries the indentation mayinclude corners, such that the indentation extends about a perimeter ofthe housing. The indentation 108 may be beading, necking, or some otherrestriction formed about the housing 105. Housing 105 may define one ormore interior regions within the housing. For example, housing 105 maydefine a first interior region 110 that may be located between the firstend 107 and the circumferential indentation 108. Housing 105 may alsodefine a second interior region 112 between the circumferentialindentation 108 and the second end 109. Housing 105 may be or include apouch, a shell, an enclosure, or a hard-casing in embodiments. Housing105 may be made of insulative materials, conductive materials, orconductive materials with an outer casing, for example. Exemplaryconductive materials may be materials that are chemically stable atcathode and/or anode operating potentials, and may include aluminum,copper, stainless steel, or other metals that may operate at anyparticular cell potential.

A set of electrodes 115 may be located within housing 105. The set ofelectrodes 115 may be positioned within the second interior region 112of the housing 105. The et of electrodes 115 may be a number ofrechargeable or primary cell designs. For example, the set of electrodes115 may be a rechargeable cell, and may be included in a rolledconfiguration, such as a jelly roll. The roll may include multiplelayers that are then rolled, stacked, or alternated up to a particularthickness to be included within housing 105. The configuration of theset of electrodes 115 may be a jelly roll in embodiments in whichhousing 105 is cylindrical through second interior region 112. Asillustrated, the set of electrodes 115 may include active material 116,and separator material 118. Separator material 118 may be anelectrically non-conducting material that may be positioned betweenanode and cathode active materials, and be configured to allow ionictransport through the structure. For example, separator material 118 maybe a polymer or a cellulosic material in embodiments. The activematerial may be disposed on current collectors described in laterfigures, and may include any number of materials.

The active materials may be or include any number of materials used inrechargeable batteries, and may include materials for a lithium-basedsystem. For example, active material 116 may include an anode materialand include a carbon-containing compound such as graphite or alithium-containing compound such as lithium titanate. Any other anodematerials may similarly be used with the present technology.Additionally, for example, active material 116 may include a cathodematerial including a lithium-containing material such as lithium cobaltoxide or lithium phosphate, among many other known lithium compoundsused in such devices. The active material 116 may also include nickel,manganese, cobalt, aluminum, and a variety of other materials that wouldbe understood to be encompassed by the present technology. Indeed, anypossible anode and cathode materials that may be incorporated within arechargeable cell as will be described below are suitable for thepresent designs, and will be understood to be encompassed by the presenttechnology.

In embodiments the set of electrodes 115 may be coupled with contactswithin the battery 100. For example, a first electrode tab 120 may be ananode tab, and may be coupled with the housing 105 as will be describedin more detail below. The battery 100 may also include a secondelectrode tab 125, which may be a cathode tab in embodiments. It is tobe understood that the electrode tabs may be reversed, or otherwisecoupled within the battery 100 in order to provide a positive andnegative terminal. Second electrode tab 125 will also be discussed infurther detail below, and in embodiments may be coupled with a cap 130.Cap 130 may be at least partially positioned within the housing 105, andmay be at least partially positioned within the first interior region110 of housing 105. Cap 130 may be characterized by a first surface 132,which may face towards the interior of the housing, and may face towardsthe set of electrodes 115. The cap 130 may also include a second surface134, which may be a surface opposite first surface 132. Second surface134 may face away from the set of electrodes, and may operate as apositive terminal, for example, during use of battery 100.

Battery 100 may include a gasket 135, which may extend about the cap130. Gasket 135 may be annular in shape, or may be characterized by anyof a variety of other geometries. Gasket 135 may couple with cap 130 tolimit or prevent contact between cap 130 and the housing 105. As cap 130may be coupled with one of the electrode tabs of the set of electrodes,and housing 105 may be coupled with another of the electrode tabs of theset of electrodes, the two components may be configured to operate atdifferent potentials, and may operate as the two battery terminals.Gasket 135 may operate to limit contact between the two terminals inembodiments. Gasket 135 may be a polymer, rubber, or any number ofinsulative materials configured to maintain cap 130 electricallydecoupled from housing 105.

Battery 100 may also include insulators positioned within the device,and may include a first insulator 140, and a second insulator 150. Firstinsulator 140 may be positioned within the housing 105. First insulator140 may extend within both first interior region 110 and second interiorregion 112, and in embodiments, first insulator 140 may extend acrosscircumferential indentation 108. First insulator 140 may extend from cap130 to the set of electrodes 115, and may contact one or bothcomponents. In some embodiments, first insulator 140 may extend towardscap 130 without contacting the component, and may extend to at least aportion of the set of electrodes 115.

First insulator 140 may be at least partially annular to allow passageof second electrode tab 125, or first insulator 140 may define a channelthrough which second electrode tab 125 may pass. First insulator 140 maybe characterized by an inner radius, which in embodiments may beconstant through a length of the first insulator 140. First insulator140 may also be characterized by an outer profile, which may beconfigured based on an interior profile of the housing 105, as well asother internal components. First insulator 140 may be characterized by afirst outer radius at a first end 142 of first insulator 140, wherefirst end 142 may be proximate cap 130. First insulator 140 may also becharacterized by a second outer radius at a second end 144 of firstinsulator 140, wherein second end 144 may be proximate the set ofelectrodes 115. The second outer radius may be greater than the firstouter radius in embodiments, although in other embodiments the firstouter radius may be greater than or equal to the second outer radius.

As illustrated the first insulator 140 may intersect the set ofelectrodes 115. For example, the set of electrodes 115 may include aseparator 118 as previously noted. The separator may extend laterally,in a rolled configuration, beyond the active materials 116 and currentcollectors. When rolled and positioned within the housing 105, theseparator 118 may define a height of the set of electrodes within thehousing 105, and the separator 118 may extend above and below activematerials 116 and the associated current collectors. The separator 118may be relatively thin and lenient to deflection based on multiplefactors including the material of the separator as well as the thicknessof the separator. The first insulator may contact the separator duringformation of the battery. The formation may include a compressionoperation in which the first insulator 140 may provide a force againstthe separator 118, which may compress, deflect, or otherwise deform theseparator 118 within the housing 105. This operation may not affect theactive material 116, and the separator may be compressed at a heightabove the active materials of the set of electrodes.

FIG. 2 shows a schematic partial cross-sectional view of energy storagedevice 100 according to embodiments of the present technology, and mayshow a more detailed view of first insulator 140. First insulator 140may be characterized by a profile at an outer radius extending along thefirst insulator. The profile may be formed to account forcharacteristics of the housing and internal components of the battery.First insulator 140 may be characterized by a chamfered or sloping edge143 extending to first end 142 of the first insulator 140. The chamferededge 143 may begin in line with the circumferential indentation 108, andmay begin below the circumferential indentation 108, such as within thesecond interior region 112. The chamfered edge 143 may taper towards cap130 in embodiments. The chamfered edge 143 may allow the first insulator140 to avoid gasket 135 in embodiments, such that the components may ormay not contact one another within a sealed battery, although thecomponents may be configured to contact each other with a minimal amountof force so as not to cause, or to cause within tolerance, an outwardcompression against the cap 130, housing 105, or any other component ofthe battery.

First insulator 140 may be further characterized by additional outerprofile characteristics including a cylindrical section 145 extendingfrom the chamfered edge 143 to an additional sloped section 147extending radially outward of an inner surface of the circumferentialindentation 108 in housing 105. The first insulator 140 may furtherinclude an additional cylindrical section 149 extending to second end144 of the first insulator 140, which may be in contact with separator118. In some embodiments, second end 144 may be characterized by anouter diameter less than 5 mm. Additional profiles encompassed by thepresent technology may be characterized by additional exterior featuresand geometries configured to form about aspects of the housing 105.

The first insulator 140 may be in contact with the cap 130 of thebattery as well as the separator 118 of the set of electrodes. By havingthe components of the battery cell in contact, and possibly undercompression, even a minor compression, components of the battery may bemaintained in line during external events. Battery 100 may becharacterized by reduced dimension in some embodiments, although battery100 may be of almost any size. The specific configuration, however, mayafford battery 100 to be on a scale of a few millimeters in diameter orsmaller in some embodiments. For example, when a device containingbattery 100 is dropped or bumped, the components within battery 100 maybe maintained in line with each other, and may be stabilized by thecontact with other components. Conventional batteries, however, may becharacterized by looser tolerances, which may allow components withinthe battery to shift within the housing. This may include the set ofelectrodes 115, which may tear, or break contact with the electrode tabsif the set of electrodes shifts or moves during a drop or other event.In the present technology, the set of electrodes 115 may be maintainedbetween one or more insulators to reduce or prevent movement during anevent such as when the device housing the battery 100 is dropped.

On batteries of reduced scale without the present technology, internalmovement of components, or shifting of materials, may allow secondelectrode tab 125 to approach or even contact circumferentialindentation 108. As previously noted, these components may be operatingat different potentials, and may be electrically coupled with theterminals of the battery 100. If the materials were shifted sufficientlyduring a drop, for example, the battery may short between the twocomponents, which in embodiments may be only 1 mm from each other orless. First insulator 140 may prevent such an occurrence, by ensuringthat at least a portion of first insulator 140 characterized by thechamfered edge 143 is maintained between the circumferential indentationof the housing 105 and an exterior component of the set of electrodes115, such as second electrode tab 125, at all times. This may beproduced by ensuring that first end 142 of first insulator 140 extendsto or beyond first surface 132 of cap 130, such as is illustrated. Putanother way, first surface 132 of cap 130 may extend within firstinsulator 140 in embodiments.

First insulator 140 may be or include a number of insulator materials,such as polymer, rubber, or some combination. For example, firstinsulator 140 may be a thermoplastic polymer, such as polypropylene, andmay be a thermoplastic polyester elastomer. The elastomers may be anynumber of materials including thermoplastic copolyesters, copolymers,olefins, polyamides, or polyurethanes. By utilizing materials such asthermoplastic polyester elastomers, the first insulator 140 may becapable to flexing during battery operation, which may swell the set ofelectrodes, and then return to the original form.

The present technology may also adjust the electrode tabs to reduce thechance of shorting events. As previously mentioned, the second electrodetab 125 may be coupled with the cathode of the set of electrodes 115.Second electrode tab 125 may extend between the set of electrodes 115and cap 130, and may be in contact with or coupled with each component.In some embodiments, second electrode tab 125 may be fixedly coupledwith both the set of electrodes 115 at the cathode, and with cap 130. Afirst end 127 of second electrode tab 125 may be coupled with firstsurface 132 of cap 130, as illustrated in FIG. 2. Cap 130 may becharacterized by a round or ovular shape in embodiments, while secondelectrode tab 125 may be rectilinear. For example, second electrode tab125 may have a rectangular end, which may include corners extendingbeyond a radius of cap 130. The present technology may adjust thegeometry of second electrode tab 125 to increase the distance betweencorners of the second electrode tab 125 and aspects of housing 105,including circumferential indentation 108.

Turning to FIG. 3 is shown a schematic partial plan view of componentsof energy storage device 100 according to embodiments of the presenttechnology. FIG. 3 illustrates a view from below cap 130, illustratingfirst surface 132. First portion 127 of second electrode tab 125 is alsoshown. The illustration includes coupling according to the presenttechnology of an adjusted second electrode tab 125. As illustrated,second electrode tab 125 may be characterized by chamfered edges 128along first portion 127 of second electrode tab 125. By formingchamfered edges 128, corners of first portion 127 may be removed, whichmay otherwise extend beyond a radius of first surface 132 of cap 130.The chamfered edges 128 may further be characterized by rounded cornersto reduce sharp points. In other embodiments the tab may becharacterized by an alternative geometry, such as a curved or roundedprofile, which may produce the same effect. Additionally, in someembodiments, the first portion may be maintained within an outer radiusof cap 130, and may have no edges or corners extending beyond the outerradius of the cap 130.

FIG. 3 also illustrates the coupling of second electrode tab 125 to cap130, which may be performed in a variety of ways. Although an adhesivemay be used in embodiments, the components may be fused or welded inembodiments to maintain conductivity between the components, or reduceresistance between the components. The coupling may utilize solder orother metal to connect the two components, or welding techniques may beused to fixedly couple the second electrode tab 125 to cap 130. Anexemplary welding technique may include laser beam welding or electronbeam welding, which may fuse the two components together. Asillustrated, the welding may include spot welds 129 in a particularorientation.

Although any number of spot welds may be utilized, and any number ofweld patterns may be formed, the coupling may include less than 5 spotwelds, such as 4 welds, 3 welds, 2 welds, or 1 weld. For example, threewelds may be formed in an exemplary coupling. The welding may beperformed such that one weld may be centrally located between chamferededges 128, such as weld 129 a. Weld 129 a relative to welds 129 b-c maybe positioned centrally to allow coupling closer to a top edge of secondelectrode tab 125. For example, weld 129 a may be positioned less than 1mm or less than 0.5 mm from an exterior edge of second electrode tab 125in embodiments. Such a weld distance from the exterior edge may not bepossible if two welds are placed adjacent one another, such as in a fourweld, square pattern. In such a scenario, the welds may be placedfurther down the tab to avoid proximity to the chamfer. Accordingly, thesecond electrode tab 125 would extend further past the welds, which mayagain extend the tab past an outer radius of first surface 132 of cap130.

First electrode tab 120 as illustrated in FIGS. 1 and 2 may also bemanufactured for use in batteries according to the present technology.First electrode tab 120, as shown schematically in FIG. 1, may becoupled with the set of electrodes 115 and may also be coupled withhousing 105. In embodiments, first electrode tab 120 may be coupled withan interior surface of battery 100. For example, first electrode tab 120may be coupled along a sidewall of housing 105 in second interior region112, proximate circumferential indentation 108. For example, firstelectrode tab 120 may be coupled adjacent circumferential indentation108, or may be coupled along a portion of housing 105 at whichcircumferential indentation 108 is formed. In other embodiments firstelectrode tab 120 may be coupled at other locations, such as with abottom portion of housing 105. First electrode tab 120 may be similarlyshaped as second electrode tab 125, and may be characterized by arectilinear design. Additionally, first electrode tab 120 may be planar,while in embodiments housing 105 may be characterized by a curvedsurface, such as with a cylindrical design.

Coupling of first electrode tab 120 with housing 105 may occur prior toor subsequent formation of the circumferential indentation, or beading,along the housing. Depending on the placement and coupling of the firstelectrode tab 120, the beading may cause further curvature of thehousing 105 against the first electrode tab 120, which may provideadditional stress to the manner of coupling. In embodiments, firstelectrode tab 120 may be welded to housing 105, or may be coupled withadhesive, fusing, or by other techniques that may produce a coupling ofthe two components and allow electrical conduction between them. Turningto FIG. 4 is shown a schematic partial cross-sectional view of energystorage device according to embodiments of the present technology. Thefigure illustrates a portion of housing 105 and first electrode tab 120.In one embodiment, projections 122 may be formed on first electrode tab120 to provide contact points for welding or fusing. The projections 122may facilitate contact across a more planar first electrode tab 120 witha curved housing 105.

The number of projections 122 may vary in different embodiments. In someembodiments, a number of projections 122 such as 1, 2, 3, 4, 5, 6 ormore projections may be formed in any pattern across first electrode tab120. The number of projections may affect the coupling in embodiments,based on the different surface features. For example, four projectionsin a square pattern may not all contact housing 105 in some embodiments,or may provide a less flush contact. When welded, such as if anelectrical current is applied to the components to form a weld, theamount of contact may affect the quality or extent of the weld. When aprojection 122 is not flush with the housing 105, the weld may be moresuperficial, or may not form at all, which may weaken the coupling ofthe components. The weld, which may also be formed by laser welding orany other form of welding, may be a point of resistance during a dropevent, and may be a stress point. When a device is dropped, movement ofthe internal components may produce stress at fixed coupling positions,such as the welded projections 122. The stress produced at the weldlocations may overcome the strength of the coupling, which may cause theelectrode tab to buckle, break, or separate from the housing 105.

As illustrated in FIG. 4, three projections 122 may be formed instead,and nested with one another in a closer configuration than fourprojections in a square pattern may be. The projections in a triangularpattern may allow all three projections 122 to contact housing 105during welding, which may ensure all three points may fully weld withhousing 105 across each projection 122 at weld points 124. Accordingly,utilizing three weld points 124 may appear to reduce the weld strengthcompared to four, for example, but by utilizing a pattern more likely toprovide flush contact on a curved surface, the three projections 122 mayenable a larger area of fusion on each projection that produces athree-point weld, which may provide an improved coupling over thecoupling that four projections may afford.

FIG. 5 shows a schematic partial cross-sectional view of energy storagedevice 100 according to embodiments of the present technology. Theillustration includes a view of a lower portion of battery 100 includinghousing 105, the set of electrodes 115, and second insulator 150. Secondinsulator 150 may be any geometry corresponding to the geometry of abase of housing 105. For example, the base of housing 105 may be roundor ovular, and second insulator 150 may be characterized by a similarshape, although in other embodiments rectangular or other polygonalgeometries may be used. Second insulator 150 may be characterized byequivalent dimensions to the base of housing 105, or may becharacterized by a radius less than a radius of the base of housing 105.

The second insulator may perform multiple functions including providingsupport for the set of electrodes 115, as well as maintaining aninsulative surface between housing 105 and the set of electrodes 115. Anouter wind of the set of electrodes 115 may include anode material,which may be at a similar potential as housing 105. However, at theexposed ends, may be access to the cathode material at differentpotential. Without second insulator 150, or some other insulativedevice, a short may occur during operation or during an event such as adrop, which may deform the separator 118 and allow contact betweencathode active material and housing 105.

Based on the possible shorting path, second insulator 150 may be formedto an equivalent radius as the base of housing 105. However, suchdimensions may produce a trap for air within the housing 105, or arestricted space along a curved base, which may cause the secondinsulator 150 to bow upward within the housing, or force the set ofelectrodes 115 further up within the housing. This may cause issues withclosing the battery components, may deform one or more components, ormay waste space within the battery, which could otherwise be used foradditional capacity. Accordingly, in some embodiments, second insulator150 may be characterized by a radius less than a radius of the base ofhousing 105, and may be characterized by a radius less than an outerradius of the set of electrodes 115. In some embodiments, an outerradius of the second insulator 150 may be less than or about 5 mm.

FIG. 6 shows a schematic plan view of a portion of a set of electrodes600 according to embodiments of the present technology. The set ofelectrodes 600 may include any of the characteristics of the set ofelectrodes 115 previously described. The set of electrodes 600 mayinclude an anode active material 610, a cathode active material 615, anda separator 620. The active materials may also include the associatedcurrent collector foils. The set of electrodes 600 also illustrates acoupling material 625 that may be included about the set of electrodes600. The coupling material may be included over a portion of the set ofelectrodes 600 to protect the set of electrodes and assist inmaintaining the structure, such as a rolled or wound structure. Thecoupling material 625 may extend about a portion of the set ofelectrodes 600, or may extend along the entire height of the set ofelectrodes 600, including along a height associated with a height of theactive materials across the set of electrodes. In some embodiments thecoupling material, which may be any of a variety of tapes, adhesives, orsleeves, may only partially extend about a circumference of the set ofelectrodes 600. However, in devices for which dropping and other contactevents may occur, the coupling material may extend fully about acircumference of the set of electrodes 600. In some embodiments, a firstend 627 of coupling material 625 may overlap a second end 629 ofcoupling material 625.

During a drop or other contact event, the ability of components to shiftwithin the battery may cause the set of electrodes to tear along one ormore surfaces. When a current collector, which may be a metal foil,tears or separates, the edges or corners may be sharp enough topenetrate or cut the separator, which may allow an electrical short tooccur. By extending coupling material 625 to overlap itself about theset of electrodes, the set of electrodes structure may be reinforced,which may resist tearing during events such as drops. It is to beunderstood that FIG. 6 is a schematic only, and is shown for exemplaryuse of an insulative material, and may not show an actual form of thematerial. For example, first end 627 may not extend as far over secondend 629, and may be coupled directly after passing an outer wind of theelectrode materials.

FIG. 7 shows a schematic cross-sectional view of a portion of anelectrode 700 according to embodiments of the present technology.Electrode 700 may be part of an anode electrode structure, and mayillustrate an outer portion of the anode electrode, which may be anouter wind of a jelly roll structure, for example. As illustrated inprevious figures, a first electrode tab 120 may be coupled with acurrent collector 705, which may be the anode current collector of theset of electrodes. The electrode tab 120 may be welded, bonded, orotherwise coupled, such as fixedly coupled with the current collector705. As illustrated, first electrode tab 120 may be coupled with a firstsurface 706 of current collector 705. First electrode tab 120 may be asimilar or different material as current collector 705. For example,both materials may be copper, nickel, stainless steel, or some otherconductive material operable at anode potential, or the components mayeach be one of these materials and be different from one another.

Current collector 705 may also be characterized by a second surface 708opposite the first surface 706. An insulating material 715, such as atape, may be applied along second surface 708, and may be positioned onthe second surface 708 over a portion of the current collector 705 towhich first electrode tab 120 is coupled. First electrode tab 120 may becoupled with current collector 705 in many ways, such as welding,bonding, fusing, or by some other coupling. For example, first electrodetab 120 and current collector 705 may be welded together with anultrasonic weld to attach the first electrode tab 120 to the currentcollector 705. Ultrasonic welding may create surface roughness or bursalong current collector 705 where the welding occurs, and may alsoproduce burs or roughness on the second surface 708 opposite thelocation of the weld. Insulating material 715 may be applied across thesecond surface 708 subsequent the welding to cover any burs. Thisinsulating material may also be applied to protect components, such as aseparator, from contacting any formed burs, which may cut or tear theset of electrodes materials.

Additionally along second surface 708 may be included an active material710, such as an anode active material. The active material 710 may belocated adjacent a portion of current collector 705 to which firstelectrode tab 120 is coupled, and may be distributed a distance fromfirst electrode tab 120 to be at least partially separated. Theseparation may be associated with the insulating material 715, which maybe positioned proximate the active material 710, and may contact oroverlap active material 710. In some embodiments, insulating material715 may be extended in both lateral directions along second surface 708beyond a portion of current collector 705 to which first electrode tab120 is coupled, and may be extended further in a direction towardsactive material 710. For example, as illustrated, insulating material715 may extend a first distance along current collector 705 in a firstdirection along second surface 708 to a first end 716 of insulatingmaterial 715.

Insulating material 715 may also extend a second distance along currentcollector 705 in a second direction along second surface 708 to a secondend 718 of insulting material 715. The second direction may be oppositethe first in embodiments, and the second direction may be towards activematerial 710, which may be distributed on current collector 705. Thesecond distance may be greater than the first distance as illustrated,and the second distance may extend towards active material 710. Thesecond distance may extend within about 5 mm of active material 710, andmay extend up to about 4 mm of active material 710, up to or about 3 mm,up to or about 2 mm, up to or about 1 mm, up to or about 0.5 mm, or lessin embodiments. In some embodiments insulating material 715 may extendin the second direction to contact or overlap a portion of activematerial 710. By extending in the second direction further towardsactive material 710, current collector 705 may be reinforced by theinsulating material 715, and may be less prone to tearing during eventssuch as a drop.

FIG. 8 shows a schematic cross-sectional view of a portion of anelectrode 800 according to embodiments of the present technology.Electrode 800 may be or include a cathode current collector 805, whichmay include a cathode active material 810 positioned or disposed on aportion of the cathode current collector 805. In embodiments, electrode800 may illustrate an end portion of a cathode current collector thatmay be included in a rolled configuration such as previously described.

During a drop or other event, an outer portion of the set of electrodes,which may be a portion of the outer winding, may tear. In embodiments inwhich the outer winding is a portion of the anode foil, the anode foilmay tear producing a relatively sharp edge, which may cut or otherwiseperforate the separator allowing contact with the cathode currentcollector. Cathode current collector 805 may include an insulating tape825 that may be used to cover any streaking of cathode active material810, and insulating tape 825 may extend over or overlap a portion ofcathode active material 810 along cathode current collector 805. In someembodiments, insulating tape 825 may be extended in a direction oppositecathode active material 810 to or towards an exterior edge 807 along alength of cathode current collector 805. The battery may be rolled in adirection along a length of the current collectors, and thus insulatingtape 825 may extend to an outer edge of the cathode current collector805, which may be at the outermost winding of the cathode currentcollector 805. By extending insulating tape 825 to an outermost edge, orexterior edge, along a length of the cathode current collector 805, thecurrent collector may be better protected against contact with an anodecurrent collector that may have punctured the separator along an outerwind of the set of electrodes.

FIGS. 9A-9C show schematic views of electrode tabs of an energy storagedevice according to embodiments of the present technology. The electrodetabs may be associated with any of the previous batteries or batterycells as previously described, and may include any of the components ofthe cells. For example, the electrode tabs may be an anode tab or acathode tab, and may be coupled with a portion of the battery housing,or a particular component of the battery, such as the cap. The electrodetabs may include any of the features or characteristics previouslydescribed above with respect to the electrode tabs. In some embodiments,electrode tab 900 may be a portion of an electrode tab coupled with acap as previously described, although the electrode tab may be either acathode associated tab or an anode associated tab, for example.Electrode tab 900 may be coupled with a first surface of the cap, suchas previously described, and may be welded, bonded, fused, adhered, orotherwise coupled with the cap.

Similar to embodiments previously described, the electrode tab 900 maybe characterized by a planar surface structure, and may be rectilinearin shape or geometry. In other embodiments, different shapes may beused, such as rounded, curved, or otherwise modified to couple with asurface of a cap or component of the battery, which may operate as aterminal. Electrode tab 900 may be coupled with a set of electrodes at afirst end of the tab, as previously illustrated, and may be coupled witha surface of the cap or other component at a second end of the electrodetab. FIG. 9A may show second end 902 of electrode tab 900. The secondend 902 of electrode tab 900 may extend to an exterior edge 904 of theelectrode tab, which may be proximate the coupling with the cap. Asillustrated, a portion of second end 902 of electrode tab 900 may becontained within an insulative material 905. Unlike conventionaltechnologies which may partially cover or sheath an electrode tabextending up from the set of electrodes towards a coupling position, thepresent technology may extend coverage past the coupling position to anexterior end of the electrode tab.

As previously discussed, the corners or edges of electrode tab 900 mayextend from the cap to which it is connected, and may extend towards ahousing of the battery, which may be at a different potential. If theelectrode tab 900 contacts the housing in such a scenario, an electricalshort may occur. Where the housing may be characterized by a cylindricalshape and may have rounded sidewalls, corners of the electrode tab maybe nearer the housing than other surfaces of the electrode tab. Byinsulating an end region of the electrode tab, an electrical barrier maybe established between the components, which may protect the electricalintegrity of the components from shorting if the battery or a devicecontaining the battery is dropped, for example. Electrode tab 900 mayalso be characterized by chamfered edges as previously described withregard to electrode tab 125.

The electrode tab 900 may be coupled with the cap by welding, fusing, orotherwise bonding the components. Additionally, the electrode tab andcap may be in electrical communication so as to operate as a terminal ofthe battery. Insulative material 905 may increase resistance betweenthese two components, or may cause bonding issues, and so in someembodiments, a window 907 may be defined by the insulative materialalong a first surface 903 of the electrode tab 900. The first surface903 may be a surface to be coupled with the cap, and the window may bedefined to expose a portion 912 of electrode tab 900. The electrode tab900 may be coupled with a cap at the exposed portion 912, which may beexposed through the insulative material 905 at window 907.

Window 907 may not expose the entire first surface 903 of electrode tab900 at second end 902. Insulative material 905 may be maintained on alledges of window 907. As illustrated, the insulative material 905 mayextend along the first surface 903 entirely around window 907, which maymaintain insulative material fully about corners at the exterior edge904 of the electrode tab 900. Although illustrated as a rectangularwindow, it is to be understood that window 907 may be formed as anyshape or geometry.

The electrode tab 900 may be characterized by additional surfacesincluding a second surface 908 as illustrated in FIG. 9B. Second surface908 may be opposite first surface 903. Second surface 908 may also becovered by insulative material 905, which may cover all exposed surfacesat a peripheral end of the electrode tab. First surface 903 and secondsurface 908 may be joined with sidewalls, such as sidewall 906, whichmay extend between the first surface 903 and the second surface 908. Asillustrated, sidewall surface 906 may also be contained or covered byinsulative material 905. The insulative material may be or include atape, polymer, or other insulative material that may be applied orcoated to the electrode tab 900 at second end 902. Window 907 may be cutout from applied insulative material, or the application process mayform the window during application of the insulative material.

FIG. 9C illustrates another view of electrode tab 900, which may showsecond surface 908. As illustrated, second surface 908 may also includecoverage or coating of insulative material 905, which may extend fullyacross second surface 908 in embodiments. Additionally, a second window910 may be defined in the insulative material 905 along the secondsurface 908 to expose a second portion 914 of electrode tab 900. Whenformed, second window 910 may be positioned relative to first window907. For example, second window 910 may be located on second surface 908opposite a position on first surface 903 at which window 907 has beendefined. The second window 910 may allow welding from below theelectrode tab 900 at second surface 908 to join or couple first surface903 with the cap. The second window 910 may have any of thecharacteristics described above for first window 907, and may be similarin shape, size, formation, or configuration. In some embodiments, secondwindow 910 may be larger or smaller than first window 907. Additionally,although window 907 may be formed during application of the insulationmaterial, in some embodiments second window 910 may be formed during thewelding or coupling process. For example, window 910 may not be formedon second surface 908. However, a welding process may apply heat,current, or some other energy from second surface 908 to couple firstsurface 903 to a cap. The welding process may burn, cut, or otherwiseremove insulative material 905 from second surface 908, which mayproduce a window 910 and expose a second portion 912 of electrode tab900. By insulating the electrode tab 900 along exterior edges of thetab, further protection from shorting may be provided during eventswhich may shift or move components within the battery.

In the preceding description, for the purposes of explanation, numerousdetails have been set forth in order to provide an understanding ofvarious embodiments of the present technology. It will be apparent toone skilled in the art, however, that certain embodiments may bepracticed without some of these details, or with additional details.

Having disclosed several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theembodiments. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent technology. Accordingly, the above description should not betaken as limiting the scope of the technology.

Where a range of values is provided, it is understood that eachintervening value, to the smallest fraction of the unit of the lowerlimit, unless the context clearly dictates otherwise, between the upperand lower limits of that range is also specifically disclosed. Anynarrower range between any stated values or unstated intervening valuesin a stated range and any other stated or intervening value in thatstated range is encompassed. The upper and lower limits of those smallerranges may independently be included or excluded in the range, and eachrange where either, neither, or both limits are included in the smallerranges is also encompassed within the technology, subject to anyspecifically excluded limit in the stated range. Where the stated rangeincludes one or both of the limits, ranges excluding either or both ofthose included limits are also included. Where multiple values areprovided in a list, any range encompassing or based on any of thosevalues is similarly specifically disclosed.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural references unless the context clearly dictatesotherwise. Thus, for example, reference to “a material” includes aplurality of such materials, and reference to “the cell” includesreference to one or more cells and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise(s)”, “comprising”, “contain(s)”, “containing”,“include(s)”, and “including”, when used in this specification and inthe following claims, are intended to specify the presence of statedfeatures, integers, components, or operations, but they do not precludethe presence or addition of one or more other features, integers,components, operations, acts, or groups.

What is claimed is:
 1. A battery comprising: a housing characterized bya first end and a second end opposite the first end, wherein the housingcomprises a circumferential indentation proximate the first end, whereinthe housing defines a first interior region between the first end andthe circumferential indentation, and wherein the housing defines asecond interior region between the circumferential indentation and thesecond end; a set of electrodes located within the housing, wherein theset of electrodes is positioned within the second interior region of thehousing; a cap at least partially contained within the first interiorregion of the housing, wherein the cap is characterized by a firstsurface facing the set of electrodes; and a first insulator positionedwithin the housing, wherein the first insulator extends across thecircumferential indentation from the cap to the set of electrodes,wherein the first insulator is characterized by a first outer radius ata first end proximate the cap, wherein the first insulator ischaracterized by a second outer radius greater than the first outerradius at a second end proximate the set of electrodes, wherein thefirst insulator is characterized by a chamfered edge extending to thefirst end of the first insulator, and wherein the first insulator issized to maintain a portion of the first insulator characterized by thechamfered edge between the circumferential indentation of the housingand an exterior component of the set of electrodes at all times.
 2. Thebattery of claim 1, wherein the set of electrodes includes a separatordefining a height of the set of electrodes, and wherein the firstinsulator is positioned within the housing in contact with theseparator.
 3. The battery of claim 2, wherein the first insulatorcompresses the separator within the housing.
 4. The battery of claim 1,further comprising an electrode tab extending from the set of electrodesto the cap, wherein the electrode tab is coupled with the cap along thefirst surface of the cap at a first end of the electrode tab, andwherein the first end of the electrode tab is characterized by chamferededges.
 5. The battery of claim 4, wherein the electrode tab is fixedlycoupled with the cap at a position on the electrode tab centrallylocated between the chamfered edges.
 6. The battery of claim 1, furthercomprising an electrode tab coupled between the set of electrodes and aninterior surface of the housing, wherein the electrode tab is coupledwith the housing in the second interior region proximate thecircumferential indentation.
 7. The battery of claim 6, wherein thecoupling of the electrode tab comprises a three-point weld.
 8. Thebattery of claim 6, wherein the electrode tab is fixedly coupled with ananode current collector of the set of electrodes along a first surfaceof the anode current collector, and wherein an insulating tape ispositioned on a second surface of the anode current collector oppositethe first surface over a portion of the anode current collector to whichthe electrode tab is coupled.
 9. The battery of claim 8, wherein theinsulating tape extends along the second surface of the anode currentcollector towards an anode active material located on the second surfaceof the anode current collector.
 10. The battery of claim 1, furthercomprising a second insulator positioned along a base of the housingbetween the set of electrodes and the housing, wherein the secondinsulator is characterized by an outer diameter less than an outerdiameter of the set of electrodes.
 11. The battery of claim 1, whereinthe set of electrodes is wound into a jelly roll, and wherein the woundset of electrodes includes coupling material extending about an exteriorsurface of the set of electrodes and characterized by a first end of thecoupling material overlapping a second end of the coupling material. 12.The battery of claim 1, wherein the battery comprises a rolledconfiguration including: a cathode current collector; a cathode activematerial positioned on a portion of the cathode current collector; andan insulating tape covering an end of the cathode active material andextending to an exterior edge along a length of the cathode currentcollector.
 13. A battery comprising: a housing characterized by a firstend and a second end opposite the first end, wherein the housingcomprises a circumferential indentation proximate the first end, whereinthe housing defines a first interior region between the first end andthe circumferential indentation, and wherein the housing defines asecond interior region between the circumferential indentation and thesecond end; a set of electrodes located within the housing, wherein theset of electrodes is positioned within the second interior region of thehousing; a cap at least partially contained within the first interiorregion of the housing, wherein the cap is characterized by a firstsurface facing the set of electrodes; a first electrode tab coupled withthe set of electrodes at a first end of the electrode tab, wherein afirst surface of the electrode tab is coupled with a surface of the capat a second end of the electrode tab, wherein the second end of theelectrode tab is contained within an insulative material, wherein afirst window is defined within the insulative material along the firstsurface of the electrode tab, and wherein the first end of the electrodetab is characterized by chamfered edges; a second electrode tab coupledbetween the set of electrodes and an interior surface of the housing,wherein the electrode tab is coupled with the housing in the secondinterior region proximate the circumferential indentation; and a firstinsulator positioned within the housing, wherein the first insulatorextends across the circumferential indentation from the cap to the setof electrodes, wherein the first insulator is characterized by a firstouter radius at a first end proximate the cap, and wherein the firstinsulator is characterized by a second outer radius greater than thefirst outer radius at a second end proximate the set of electrodes. 14.The battery of claim 13, wherein the set of electrodes includes aseparator defining a height of the set of electrodes, and wherein thefirst insulator is positioned within the housing in contact with theseparator.
 15. The battery of claim 14, wherein the first insulatorcompresses the separator within the housing.
 16. The battery of claim13, wherein the first insulator is characterized by a chamfered edgeextending to the first end of the first insulator.
 17. The battery ofclaim 16, wherein the first insulator is sized to maintain a portion ofthe first insulator characterized by the chamfered edge between thecircumferential indentation of the housing and an exterior component ofthe set of electrodes at all times.
 18. The battery of claim 13, furthercomprising a second insulator positioned along a base of the housingbetween the set of electrodes and the housing, wherein the secondinsulator is characterized by an outer diameter less than an outerdiameter of the set of electrodes.